Douglas Bantam Restoration

[Chris]

Hi all,
I commenced my Bantam restoration with the collection of components shown in the "before" photograph. There were three types of forks used on Bantam and the forks that came with the "kit" were the rarer tubular girder version. I partially restored these before I was offered a pair of the more usual pressed steel forks by a member of the London Douglas MCC. "They have been under my bench for years". (The tubular girders are now being used in another Bantam restoration). Other parts were incorrect and were either, modified, replaced or manufactured with the aim of making the machine as original as possible within reason. Particularly difficult items were the aluminium castings for the gear change housing and the exhaust waffle box. For these I made the wooden patterns and the core box (plaster of Paris) and had them cast by a local non-ferrous foundry The machining of the waffle box was carried out on my bench drill using a home made boring tool to provide bores of the correct diameter and distance apart to provide a correct fit onto the parallel outlet ports of the cylinder barrel and also for the exhaust pipe outlets. I was fortunate to be able to borrow a nearly complete Bantam to enable so many missing parts to be copied. The loan of an original leg-shield from another Club member enabled manufacture of these using wire rolled edges. Strengthening ribs were rolled in using a borrowed "Jenny" for which I made the rollers. Another interesting exercise was the creation of the badge on the flywheel cover. This was made using clear casting resin incorporating the Scotsman's head transfer available from The LDMCC. It was cast in a wax mould formed around a glass light bulb (60 watt) to give a highly polished finish. A complete list of the parts I made in restoration of this machine is attached. The other photos show the restored machine from both sides and views of the "works" with the side panels removed.
Chris

As it was pre-restoration:


Larger view HERE

Post restoration - right-hand side:


Larger view HERE

Post restoration - left-hand side:


Larger view HERE

The engine room - right-hand side:


Larger view HERE

The engine room - left-hand side:


Larger view HERE

And here is a list of the replacement parts that I had to replicate....

Parts for Bantam Restoration

Rear brake rod Knurled rear Brake adjuster Brake lever securing bolts - 2 Front Brake rod and clevis fork Clevis pin -3 Front brake spring box Front brake knurled adjuster Front brake knurled lock ring Front mudguard stays - 2 Brake band pivots - 4 Brake band adjusting bolts - 3 Rear mudguard stay Rear mudguard grab bar. Front number plate Rear number plate Rear mudguard Footrest assemblies - 2 Gearbox platform Rear engine mounting Side panel mounting clamps - 2 Side panels - 2 Side panel knobs - 4 Gear change gate Gear lever Gear lever pivot Gear change rod Knee pad plates - 2 Knee pad studs - 2 Screws for gear change casting - 2 Engine shock absorber Spring Engine shock absorber nut Crankshaft nut Manifold bolts - 2

Manifold studs - 2 Manifold adaptor Crankcase studs - 4 Crankcase bolts - 4 Engine front mounting bolts - 2 Engine rear mounting bolts - 2 Engine top mounting bolts - 2 Front engine clamp bolts - 2 Front engine clamp spacers - 2 Rear wheel spindle Rear wheel adjuster bolts Rear hub Rear brake plate Clutch Crankshaft Brake and clutch reverse levers Saddle frame Rear brake lever Change speed lever Headlamp Grease nipples Handlebars Front and rear spindle nuts LH - 4 Front spindle stepped washers Fork spindles - 4 Fork spindle nuts - 4 Fork bearing bushes - 4 Headlamp support brackets - 4 Steering head clamp stud Oil measure Banjo bolts - 2 Petrol pipe Gearbox large headed blanking bolt

Rear seat studs Saddle front spring Clutch push rod Clutch lever pivot Gearbox sprocket Mud flap Mud flap clamp strip Petrol tank supports Air lever screw Dynamo support bracket Frame bolt Rear stay studs Flywheel cover badge Rear stand Rear stand clip bolt Rear stand pivot bolts Twist grip helix tube Twist grip slider Twist grip clamp ring Chain guard Cables - Clutch, Brake, De-compressor Drain tap adaptor Exhaust brackets - 2 Tool box knob Gear change casting Exhaust waffle box Waffle box clamp Waffle box clamp bolt Tool box Toolbox clamp Badge mounting Leg shields Handlebar "U" bolts

[graeme]

That is a wonderful transformation Chris! What a superb restoration. Makes me wish that my dad had grabbed the Bantam we saw some years back, missing most of the tinware, but in better nick than what you started with. I know where it is  - let's hope it gets a similar transformation,eh Daren!

[trevorp]

hats of to u chris what a brilliant job

[Dave]

Chris,

Can you tell us which year and model the Bantam is? - if that's possible. I understand there were a few different models of the Bantam between 1933 and 1935. We're organising a collection of members' photos by model and would like to include yours with the correct title.

cheers, Dave
 

[Chris]

MY Bantam is the 1935 model 5X.1 i.e. top of the (limited) range with dynamo lighting and battery.

[ericseguy]

hy,
i 'm live in france, i have find a bantam douglas in 6 years ago, it was completed with all pieces. I think this model is difficult to find, i have seen only yours and mine.  After one year of restauration you can look for it:

[Chris]

Hi Eric
       It is good to see another restored Bantam. It illustrates however, some of the variations of this model which is known to have used two different petrol tanks, three different front forks, three different designs of side panels, two different frames, two different alloy silencer boxes under the engine, three different exhaust silencers at the rear, and of course two different engines. I know of three other Bantams in England that are complete and in running condition, another being restored and one being restored in Australia.
Chris.

[Daren W Australia]

How about this pic taken about 1948 Daren



Frank Harrison c1948 with Douglas Bantam

[graeme]

Interesting to see that white rubber tyres were still available then - I thought they disappeared in the beaded edge era.

[TonyC]

Hi,

Can anyone give details of the dynamo that is fitted to the Bantam especially the model in the lower picture, ie sizes and make.

Thanks

Tony

[Cliffy73]

Hi Nice job on the restoration. Me and my dad are just start restoring a Bantam each. Mine is a model X and my dad's is a 5X1. I'm after parts for the 5X1 if you have any spare parts. Cheers Chris.

[Bob M]

As a sad Villiers obsessive I confess my Bantam interest lies solely with the first Villiers powered version. Why Douglas dropped the Villiers for their own make engine I do not know but then again, I am a little biased.
Just as a matter of Douglas interest you may like to know the Villiers engine used was their 148cc Mk XIIC introduced in 1931 and made until 1940. It is more or less the standard Villiers factory offering with only change I’ve found to date being the position of the crankcase drain plug. It was moved to suit the horizontal engine position used on the Bantam. It would otherwise have been on the centreline level with the crankshaft. Not very effective as a drain plug up there.
Villiers did give it it’s own engine number prefix, GYH, as compared to the standard engine GY prefix. That was common Villers practice back then when they made minor changes to meet a specific makers need. The mechanicals always remained the same but there could be little oddities as in this case.
I suspect I may also have a Villiers Bantam inlet manifold in the shed. Villiers made a huge range of inlet manifolds to the extent they wouldn’t list them in their spare parts list but just bluntly told customers they couldn’t supply unless they received a sample to refer to. Mine is of a U shape lying on its side. It would appear spot on for the horizontal Bantam engine but as I said, Villiers made an exhaustive number of inlet manifolds so who knows.
Cheers, Bob